Motor having a noise filter

ABSTRACT

A motor may include a housing, a motor assembly accommodated in the housing, and a mold cover having an outer circumferential surface. The outer circumferential surface may be coupled to the housing, which has electrical conductivity. A noise filter is provided in the mold cover. A ground terminal of the noise filter is electrically connected to the outer circumferential surface of the mold cover.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a Continuation Application of prior U.S. patentapplication Ser. No. 14/567,053 filed Dec. 11, 2014, which claimspriority under 35 U.S.C. § 119 to Korean Application No. 10-2013-0154013filed on Dec. 11, 2013, whose entire disclosures are incorporated hereinby reference.

BACKGROUND 1. Field

The present application relates to a motor capable of lowering anelectromagnetic noise level.

2. Background

In general, a motor may be classified into a brush motor and a brushlessmotor (BLDC motor). In the above two kinds of motors, the brush motorhas been universally and widely utilized and has been employed invarious industrial environments due to a relatively inexpensive cost ascompared with the brushless motor.

In the direct current brush motor (DC motor) a permanent magnet isemployed as a stator, a coil is provided as a rotor, and a repulsiveforce and an attractive force are generated between the rotor and thestator by converting a flow direction of the current flowing in therotor so that a rotational force is generated. Most direct current brushmotors employ a commutator and a brush for converting the flow directionof the current.

According to a mechanical motion of such a direct current brush motor,however, when a coil is rotated, a polarity of the coil is changed dueto a mechanical contact point caused by the brush and the commutator,and a spark is then generated by a counter electromotive force of thecoil. Due to the above, a considerably high electromagnetic noise isgenerated. Such electromagnetic noise influences an operation of theequipment itself in which an electromagnetic wave is generated or otherequipment so that this electromagnetic noise causes a functionaldisorder or malfunction of the equipment.

As one of the methods for removing the electromagnetic noise, a methodin which a noise filter is installed to transfer the electromagneticwave generated between the brush and the commutator of the directcurrent brush motor to the ground via a housing and to remove it hasbeen employed. However, the above method is disadvantageous in that acontact area between a ground terminal of the noise filter and thehousing is small and the noise is not rapidly removed due to thislimitation.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments will be described in detail with reference to thefollowing drawings in which like reference numerals refer to likeelements wherein:

FIG. 1 is an exploded perspective view of a motor according to oneembodiment of the present application;

FIG. 2 is a conceptual view of a motor provided with a noise filteraccording to one embodiment of the present application;

FIG. 3 is a conceptual view concretely showing the noise filter shownFIG. 2;

FIG. 4 is a conceptual view showing a state where a ground terminal of anoise filter according to one embodiment of the present application iselectrically connected to a mold cover;

FIG. 5 is a view showing a modified example of the structure shown inFIG. 4;

FIG. 6 is a conceptual view showing a state where a mold cover accordingto one embodiment of the present application is inserted in a housing;and

FIG. 7 is a graph illustrating a state where a noise level of a motoraccording to one embodiment of the present application is reduced.

DETAILED DESCRIPTION

Referring to FIG. 1, a motor includes a housing 10, a motor assembly 300received in the housing 10, and a mold cover 50 having an outercircumferential surface coupled to the housing 10. The outercircumferential surface of the mold cover has conductivity.

The housing 10 has a cylindrical shape and is provided with a spaceformed therein so that the motor assembly 300 can be mounted in thespace. The shape or material for the housing 10 may be variouslychanged. A metal material which can withstand a high temperature may beselected for the housing 10.

The mold cover 50 and a lower cover 11 are coupled to the housing 10 toshield a stator 20 and a rotor 30 from the outside. The housing 10 mayfurther include a cooling structure for easily discharging internalheat. An air-cooling type cooling structure or a water-cooling typecooling structure may be selected as a cooling structure, and a shape ofthe housing 10 may be properly modified depending on the coolingstructure.

The motor assembly 300 disposed in the housing 10 includes the stator20, the rotor 30, and a rotational shaft 40. A plurality of split-ringshaped magnets are arranged on the stator 20, and this stator can beinserted into the internal space of the housing 10. The stator is notlimited to the above, and a coil may be wound around a stator core toform the stator.

The rotor 30 includes a rotor core 32 around which a plurality of coilsare wound and a commutator 31 mounted to the rotor core 32. Thecommutator 31 is in contact with a brush mounted to the mold cover 50.One end of the brush is connected to an external power source and theother end is in contact with the commutator 31 to supply the power tothe commutator 31. The above structure of the motor may include all thecomponents of a direct current motor provided with the brush.

The mold cover 50 may be manufactured by an injection-molding processwith a non-conductive material. A brush connected to the commutator 31and a noise filter are provided on the mold cover 50. The outercircumferential surface of the mold cover 50 is fitted in the housing 10so that the mold cover is inserted in the housing.

Referring to FIG. 2, a conductive layer 51 is formed on an outer surfaceof the mold cover 50. The conductive layer 51 is formed on an outercircumferential surface 50 a of the mold cover 50 and may be extended toa rear surface 50 b. Once the mold cover 50 is inserted in the housing10, the conductive layer 51 formed on the outer circumferential surface50 a of the mold cover 50 become in contact with an innercircumferential surface 10 a of the housing 10 so that the mold coverand the housing are electrically connected to each other.

A well-known structure for supplying direct current power to the motorassembly 300 may be employed as a power supplying part 100. As oneexample, the power supplying part 100 may be configured of a brush and acommutator connected to an external power source.

A noise filter 200 may be ground-connected to the conductive layer 51.In addition, since the conductive layer 51 is electrically connected tothe inner circumferential surface of the housing 10, a contact area iswidened. Consequently, by utilizing a large ground-connection, it ispossible to rapidly remove noise.

Referring to FIG. 3, the noise filter 200 includes a first electricstorage unit 230, 240, a second electric storage unit 260, a firstinductor 210, and a second inductor 220. The first electric storage unit230, 240 is called as the Y capacitor (Y cap) and can bypass the noiseto ground terminals 250.

The first electric storage unit 230, 240 includes a first capacitormodule 230 connected to the first inductor 210 and the power supplyingpart 100 and a second capacitor module 240 connected to the secondinductor 220 and the power supplying part 100. The first capacitormodule 230 includes a first capacitor 231 and a second capacitor 232,and the second capacitor module 240 includes a third capacitor 241 and afourth capacitor 242.

For clearly illustrating the structure of the noise filter, FIG. 3 showsthat the first capacitor module 230 and the second capacitor module 240are connected to different ground terminals 250. In practice, however,the first capacitor module 230 and the second capacitor module 240 areconnected to one common ground terminal 250.

The second electric storage unit 260 is called as the X capacitor (Xcap), and this electrical storage unit can act as a matching capacitorfor matching an impedance of a circuit or can perform the function ofinhibiting differential mode noise generated by a differential modecurrent component.

The ground terminal 250 of the noise filter 200 may be directlyconnected to the conductive layer 51, but may be electrically connectedto the conductive layer 51 through a contact pin 52 which isadditionally and separately provided. Depending on a thickness of thecontact pin 52, a recess in which the contact pin 52 is inserted may beprovided on the mold cover 50.

FIG. 4 illustrates a state where the ground terminal of the noise filteraccording to one embodiment of the present application is electricallyconnected to the mold cover, and FIG. 5 is a view showing a modifiedexample of the structure shown in FIG. 4.

Referring to FIG. 4, the first capacitor module 230 and the secondcapacitor module 240 are electrically connected to the contact pin 52 bysoldering portions S, respectively. In addition, the contact pin 52 iselectrically connected to the conductive layer 51 through a conductivetape 53. In order to minimize a contact resistance between theconductive tape 53 and the contact pin 52, it is preferable that a sizeof the conductive tape be larger than an area of the contact pin.

The conductive layer 51 can be formed on a lower surface as well as theouter circumferential surface of the mold cover 50. In a case where theconductive layer 51 is formed on the lower surface of the mold cover 50,the noise generated from the inductors 210 and 220 is directlytransferred to the housing 10. In other words, the conductive layer 51formed on the lower surface of the mold cover 50 can act as the elementwhich bypasses the noise generated from the inductors 210 and 220 to thehousing 10.

The conductive layer 51 may be formed of at least one selected from thegroup consisting of nickel, silver, gold, aluminum, tungsten, and zinc.The conductive layer 51 may be deposited on the overall outer surface ofthe mold cover 50 by a spray method, but the present application is notlimited thereto. The conductive layer may be formed by attaching aconductive film on the overall outer surface of the mold cover.

When considering an assembly tolerance of the housing 10 and the moldcover 50, the conductive tape 53 may have a thickness of 30 to 90 μm andthe conductive layer 51 has a thickness of 1 to 10 μm. If the thicknessof the conductive layer 51 is less than 1 μm, the conductive layer maynot have sufficient conductivity, and if the conductive layer 51 may nota thickness greater than 10 μm, the conductive layer 51 cannot beuniformly formed on the mold cover 50 or may detach from the mold cover.

The sum of thicknesses of the contact pin 52, the conductive layer 51,and the conductive tape 53 should be 100 μm or less. If the sum ofthicknesses of the contact pin 52, the conductive layer 51, and theconductive tape 53 exceeds 100 μm, the overall diameter of the moldcover 50 may become excessively large so that a failure of couplingbetween the mold cover and the housing 10 occurs.

Referring to FIG. 5, if a contact pin 52 a has a large area, theconductive tape 53 can be omitted. In other words, all the structures inwhich the first electric storage unit 230, 240 can be stably connectedto the conductive layer 51 can be applied to the present application.

For example, the contact pin 52 a is omitted, and a wire W of the firstelectric storage unit 230, 240 can be directly connected to theconductive layer 51 using the conductive tape. Alternatively, theconductive layer 51 is omitted, and it is possible to electricallyconnect to the housing with only the contact pin 52 and the conductivetape.

FIG. 6 illustrates a state where the mold cover according to oneembodiment of the present application is inserted in the housing, andFIG. 7 is a graph illustrating a state where a noise level of the motoraccording to one embodiment of the present application is reduced.

Referring to FIG. 6, the housing 10 includes a ground innercircumferential surface 10 a which is electrically connected to theouter circumferential surface of the mold cover 50. In the backgroundstructure, since the noise filter is in contact with the housing throughthe contact pin, a contact area is small. According to the presentapplication, however, since the entire conductive layer 51 formed on theouter circumferential surface of the mold cover 50 is in contact withthe ground inner circumferential surface 10 a of the housing 10, acontact area can be maximized to effectively lower the noise level.

Therefore, the ground inner circumferential surface 10 a may have anarea corresponding to an area of the outer circumferential surface ofthe mold cover 50 inserted in the housing 10. If needed, an additionalconductive member may be attached to the ground inner circumferentialsurface 10 a of the housing 10. The reference numeral 50 c which is athrough hole through which a rotational shaft of the motor passes.

Referring to FIG. 7, it can be known that, as compared with thebackground structure A, the noise level of the motor B according to thepresent application is remarkably lowered. From FIG. 7, it can be seenthat, as compared with the background structure, the noise level islowered by 10 dB or more in the frequency range of 200 to 960 MHz whichis the most important frequency range of the motor. This is because acontact area is maximized and a contact resistance is reduced to enablethe noise to be rapidly removed.

The grounding area of the noise filter is increased so that it ispossible to effectively lower the electromagnetic noise level.

It is possible to rapidly bypass the noise generated from the inductorof the noise filter to the housing.

A motor can lower an electromagnetic noise level through a novelstructural modification.

A motor according to a preferred embodiment of the present applicationmay include a housing; a motor assembly accommodated in the housing; amold cover having an outer circumferential surface, the outercircumferential surface being coupled to the housing and havingconductivity; and a noise filter accommodated in the mold cover. Here, aground terminal of the noise filter is electrically connected to theouter circumferential surface of the mold cover.

The mold cover may include a conductive layer formed on the outercircumferential surface thereof, and the ground terminal of the noisefilter is electrically connected to the conductive layer. The conductivelayer may be extended to a rear surface of the mold cover.

The motor may further include a contact pin disposed between the groundterminal of the noise filter and the conductive layer. The motor mayfurther include a solder portion electrically connecting the groundterminal of the noise filter to the contact pin. The motor may furtherinclude a conductive tape by which the contact pin is attached to theconductive layer.

The conductive layer may have a thickness which is less than that of theconductive tape. The sum of thicknesses of the contact pin, theconductive layer, and the conductive tape may be 100 μm or less. Thenoise filter may include a first electric storage unit connected to theground terminal. The first electric storage unit may include a firstcapacitor module connected to a first inductor and a second capacitormodule connected to a second inductor.

The motor assembly may include a stator accommodated in the housing; arotor; a commutator coupled to the rotor; and a rotational shaft whichis rotated integrally with the rotor. The housing may include a groundinner circumferential surface which is in contact with the mold cover,and the ground inner circumferential surface has the conductivity. Thehousing may include a conductive member attached to the ground innercircumferential surface.

A motor according to the present application may include a housing; amotor assembly accommodated in the housing; a mold cover coupled to thehousing; and a noise filter accommodated in the mold cover. Here, thehousing includes a ground inner circumferential surface which iselectrically connected to a ground terminal of the noise filter. An areaof the ground inner circumferential surface may correspond to an area ofan outer circumferential surface of the mold cover.

Any reference in this specification to “one embodiment,” “anembodiment,” “example embodiment,” etc., means that a particularfeature, structure, or characteristic described in connection with theembodiment is included in at least one embodiment of the invention. Theappearances of such phrases in various places in the specification arenot necessarily all referring to the same embodiment. Further, when aparticular feature, structure, or characteristic is described inconnection with any embodiment, it is submitted that it is within thepurview of one skilled in the art to effect such feature, structure, orcharacteristic in connection with other ones of the embodiments.

Although embodiments have been described with reference to a number ofillustrative embodiments thereof, it should be understood that numerousother modifications and embodiments can be devised by those skilled inthe art that will fall within the spirit and scope of the principles ofthis disclosure. More particularly, various variations and modificationsare possible in the component parts and/or arrangements of the subjectcombination arrangement within the scope of the disclosure, the drawingsand the appended claims. In addition to variations and modifications inthe component parts and/or arrangements, alternative uses will also beapparent to those skilled in the art.

What is claimed is:
 1. A motor, comprising; a housing; a motor assemblydisposed in the housing; a mold cover having an outer circumferentialsurface coupled to the housing and a rear surface disposed on the outercircumferential surface, wherein the mold cover includes anon-conductive material; a noise filter disposed in the mold cover andincluding a ground terminal; and a conductive layer disposed on theouter circumferential surface of the mold cover and the rear surface ofthe mold cover, wherein an outer circumference surface of the conductivelayer is in contact with an inner surface of the housing; and a contactpin electrically coupled to the ground terminal, wherein the groundterminal of the noise filter is electrically connected to the outercircumferential surface of the conductive layer, wherein at least aportion of the contact pin is disposed between an inner surface of thehousing and the outer circumferential surface of the conductive layer,the portion of the contact pin is directly contacted to the innersurface of the housing and is directly contacted to the outercircumference surface of the conductive layer.
 2. The motor of claim 1,wherein the contact pin is disposed between the ground terminal of thenoise filter and the conductive layer.
 3. The motor of claim 2, furthercomprising a solder portion electrically connecting the ground terminalof the noise filter to the contact pin.
 4. The motor of claim 2, furthercomprising a conductive tape by which the contact pin is attached to theouter circumferential surface of the conductive layer.
 5. The motor ofclaim 4, wherein the conductive layer has a thickness which is less thanthat of the conductive tape.
 6. The motor of claim 4, wherein the sum ofthicknesses of the contact pin, the conductive layer, and the conductivetape is 100 μm or less.
 7. The motor of claim 1, wherein the noisefilter comprises a first electric storage unit connected to the groundterminal.
 8. The motor of claim 7, wherein the first electric storageunit comprises a first capacitor module connected to a first inductorand a second capacitor module connected to a second inductor.
 9. Themotor of claim 1, wherein the motor assembly comprises a statoraccommodated in the housing; a rotor; a commutator coupled to the rotor;and a rotational shaft which is rotated integrally with the rotor. 10.The motor of claim 1, wherein the housing comprises a ground innercircumferential surface in contact with the conductive layer, and theground inner circumferential surface has conductivity.
 11. The motor ofclaim 10, wherein the housing comprises a conductive member attached tothe ground inner circumferential surface.
 12. The motor of claim 1,wherein the conductive layer is formed of one of nickel, silver, gold,aluminum and zinc.